US4623496A - Method of manufacturing an optical element having an aspheric surface - Google Patents

Method of manufacturing an optical element having an aspheric surface Download PDF

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Publication number
US4623496A
US4623496A US06/683,094 US68309484A US4623496A US 4623496 A US4623496 A US 4623496A US 68309484 A US68309484 A US 68309484A US 4623496 A US4623496 A US 4623496A
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United States
Prior art keywords
substrate
matrix
synthetic resin
layer
curvature
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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US06/683,094
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English (en)
Inventor
Johannes M. G. Verhoeven
Albert Smid
Herman M. A. Amendt
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US Philips Corp
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US Philips Corp
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Assigned to U.S. PHILIPS CORPORATION reassignment U.S. PHILIPS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: AMENDT, HERMAN M. A., SMID, ALBERT, VERHOEVEN, JOHANNES M. G.
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Publication of US4623496A publication Critical patent/US4623496A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00019—Production of simple or compound lenses with non-spherical faces, e.g. toric faces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
    • Y10S425/808—Lens mold

Definitions

  • the invention relates to a method of manufacturing an aspherical optical element.
  • the aspherical optical element includes a substrate having an approximately spherical surface and a synthetic resin correction layer provided on the spherical surface.
  • the free surface of the correction layer is convex aspherical and has a collection of inflection points situated approximately on a circle.
  • the substrate is placed opposite to and spaced from a rotationally symmetrical matrix which has a concave aspherical surface having a collection of inflection points situated approximately on a circle.
  • a curable liquid synthetic resin composition is provided between the matrix and the substrate, and the distance between the matrix and the substrate is reduced to a desired final position.
  • the synthetic resin composition is the cured, and the substrate together with the correction layer, the connected thereto, are removed from the matrix.
  • the invention also relates to a device for performing the method, and the aspherical optical element made by the method.
  • the method may be used, for example, for manufacturing monaspherical.
  • British Pat. No. 1,301,551 discloses a method of manufacturing an aspherical optical element by providing a thermosetting layer of synthetic resin on a flat or spherical substrate, for example for correction of aberration.
  • the variation in thickness of the layer of synthetic resin must be in agreement with the desired correction.
  • a positive curvature may be necessary in the center of the optical element and a negative curvature may be necessary at the edge. In between, a collection of inflection points exists on the surface of the correction layer.
  • the correction layer may be made thinner by providing the substrate with approximately the desired surface, but a spherical substrate can be manufactured more simply and more accurately than a substrate having an aspherical surface.
  • a guiding mechanism may be provided to keep the matrix and the substrate in their desired positions.
  • thermosetting resin is used in the method described in British Pat. No. 1,301,551.
  • synthetic resin may be light-curable, as described, for example, in German Patent Application No. 2,637,257 (corresponding to British Pat. No. 1,535,986).
  • this object is achieved by a method in which the spherical surface of the substrate has a radius of curvature closen such that the synthetic resin layer has a minimum thickness adjacent to the collection of inflection points.
  • the invention is base on the discovery of the fact that the radius of curvature of the spherical surface of the substrate can be chosen freely within certain limits.
  • the correction layer also functions to correct the focal distance.
  • the substrate and the matrix approach each other most closely near a collection of points which are situated on a circle.
  • This diameter of the circle is not too small, so that accurate positioning is possible.
  • Such accurate positioning is not possible when the radius of curvature of the spherical surface of the substrate is so small that the substrate and the matrix approach each other most closely near a single point approximately in the center of the matrix and the substrate.
  • the thickness of the correction layer at the outer edge becomes undesirably large. As a result, shrinkage problems arise during curing.
  • the radius of curvature of the spherical surface of the substrate is so large that the substrate and the matrix approach each other most closely near the outer edge of the substrate, then accurate positioning is possible. However, in that case the thickness of the correstion layer is too large in the center. This again gives rise to shrinkage problems.
  • the differences in thickness in the correction layer are approximately twice as large as when these points are situated adjacent to the collection of inflection points.
  • FIG. 1 is a cross-sectional view of a substrate and a matrix according to the invention
  • FIG. 2 is a cross-sectional view of a substrate with a correction layer according to the invention.
  • FIG. 3 is a cross-sectional view of a substrate and a matrix not according to the invention.
  • FIG. 4 is a cross-sectional view of a substrate and a matrix not according to th invention.
  • FIG. 5 is a cross-sectional view of a substrate and a device according to the invention.
  • FIG. 1 is a cross-sectional view of a matrix 1, for example made of glass or a metal.
  • the inner surface 2 of matrix 1 matches the desired outer surface of the correction layer.
  • the substrate 3 may be manufacutred, for example, from glass or a transparent synthetic resin.
  • Substrate 3 has an approximately spherical outer surface 4.
  • a quantity of a curable liquid synthetic resin composition is provided between the surfaces 2 and 4. Then the distance betwween the matrix 1 and the substrate 3 is reduced to a desired position. Finally, the curable synthetic resin composition is cured.
  • the curable liquid synthetic resin composition may be provided between the matrix 1 and the substrate 3 after they have been placed opposite each other, but it is efficacious to first provide a drop of the curable synthetic resin composition on the substrate or on the matrix and then press the substrate and matrix together.
  • curable synthetic resin composition depends on the requirements which are imposed on the correction layer, for example as regards hardness, light transmission and refractive index.
  • Suitable starting materials are monomeric or oligomeric acrylates, for example the diglycidyl ether of bisphenol A with which ⁇ , ⁇ -dimethoxy- ⁇ -phenyl acetophenone may be used as an initiator.
  • This synthetic resin may be made to cure under UV light, for example by exposure to the light of a medium-pressure mercury lamp having a wavelength of 360 nm for 1 minute.
  • FIG. 2 is a cross-sectional view of the substrate 3 bearing a correction layer 5.
  • the free surface 6 of correction layer 5 has desired aspherical shape.
  • the diameter of the substrate 3 may be, for example, 5 mm. If in that case a weight of 30 g is used to compress the substrate 3 and the matrix 1 during curing of the synthetic resin layer 5, the smallest thickness of the correction layer 5 after curing will be approximately 1 ⁇ m (adjacent to the substantially circular collection of inflection points) as a result of capillary forces. In that case the largest thickness in the center is 7-15 ⁇ m and the largest thickness at the outer edge is approximately 15 ⁇ m.
  • the desired radius of curvature of the spherical surface 4 of the substrate 2 according to the invention can be simply determined geometrically from a drawing or by a few experiments in which an accuracy of a few microns is necessary. Control of the place where the synthetic resin layer has the smallest thickness is possible, for example, by measuring interference rings.
  • FIG. 3 is a cross-sectional view of a matrix 1 and a substrate 7.
  • Substrate 7 has a surface having such a small radius of curvatue that the matrix 1 and the substrate 7 approach each other most closely near the center of the matrix 1 and the substrate 7.
  • the thickness of the correction layer at the outer edge is approximately twich as large as in the example according to the invention.
  • the matrix 1 and the substrate 7 are not accurately positioned relative to each other because lateral displacement of the substrate 7 with respect to the matrix 1 is possible unless the two are pressed together very strongly.
  • FIG. 4 is a cross-sectional view of a matrix 1 and a substrate 8.
  • substrate 8 has a surface having such a large radius of curvature that the matrix 1 and the substrate 8 approach each other most closely near the outer edge of the substrate 8.
  • the thickness of the correction layer 5 in the center is approximately twich as large as in the example according to the invention. As a result, the synthetic resin layer 5 shrinks considerably in the center on curing to form surface irregularities.
  • FIG. 5 is a cross-sectional view (not drawn to scale) of a substrate and a device according to the invention.
  • the device includes a light transmitting matrix 9 bearing on an annular support 10.
  • a substrate 3 having surface with a radius of curvature according to the invention is present above the matrix 9. Both the substrate 3 and the matrix 9 have flat rear surfaces.
  • a quantity of a curable liquid synthetic resin composition 5 is provided between the matrix 9 and the substrate 3.
  • the substrate 3 is pressed toward matrix 9 by a plate 11.
  • Plate 11 is parallel to the support 10 and can be moved between guides 12 with respect to the support 10.
  • the plate 11 is pressed against the substrate 3 with an accurately determined force, for example, by a weight 13. Plate 11 therefore orients the substrate parallel to matrix 9 as the substrate and matrix are pressed together.
  • the curable liquid synthetic resin composition 5 may be cured by exposure to the light of an urltrviolet lame 14. The light from lamp 14 reaches the resin 5 by passing through the matrix 9.

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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ophthalmology & Optometry (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
US06/683,094 1984-01-18 1984-12-18 Method of manufacturing an optical element having an aspheric surface Expired - Lifetime US4623496A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL8400152 1984-01-18
NL8400152A NL8400152A (nl) 1984-01-18 1984-01-18 Werkwijze voor de vervaardiging van een optisch element, inrichting voor toepassing van de werkwijze en optisch element vervaardigd met de werkwijze.

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US06/884,247 Division US4738516A (en) 1984-01-18 1986-07-10 Optical element having an aspheric surface

Publications (1)

Publication Number Publication Date
US4623496A true US4623496A (en) 1986-11-18

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ID=19843342

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US06/683,094 Expired - Lifetime US4623496A (en) 1984-01-18 1984-12-18 Method of manufacturing an optical element having an aspheric surface
US06/884,247 Expired - Lifetime US4738516A (en) 1984-01-18 1986-07-10 Optical element having an aspheric surface

Family Applications After (1)

Application Number Title Priority Date Filing Date
US06/884,247 Expired - Lifetime US4738516A (en) 1984-01-18 1986-07-10 Optical element having an aspheric surface

Country Status (8)

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US (2) US4623496A (cs)
EP (1) EP0150537B1 (cs)
JP (1) JPS60154014A (cs)
KR (1) KR850005324A (cs)
CS (1) CS252824B2 (cs)
DD (1) DD231315A5 (cs)
DE (1) DE3470686D1 (cs)
NL (1) NL8400152A (cs)

Cited By (27)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4944899A (en) * 1985-03-19 1990-07-31 Coopervision, Inc. Process and apparatus for casting lenses
WO1991008104A1 (en) * 1989-12-05 1991-06-13 Vision Science, Inc. Method for forming plastic optical quality spectacle
US5147585A (en) * 1987-10-30 1992-09-15 Blum Ronald D Method for forming plastic optical quality spectacle lenses
US5178800A (en) * 1990-10-10 1993-01-12 Innotech, Inc. Method for forming plastic optical quality spectacle lenses
US5219497A (en) * 1987-10-30 1993-06-15 Innotech, Inc. Method for manufacturing lenses using thin coatings
US5264160A (en) * 1991-04-30 1993-11-23 Canon Kabushiki Kaisha Method of molding optical elements
US5286421A (en) * 1991-06-07 1994-02-15 Canon Kabushiki Kaisha Optical element, and method and apparatus for forming the same
US5290488A (en) * 1991-04-30 1994-03-01 Canon Kabushiki Kaisha Method for molding optical elements
US5292457A (en) * 1991-04-30 1994-03-08 Canon Kabushiki Kaisha Method for molding optical elements
AU648209B2 (en) * 1991-11-29 1994-04-14 Sola International Inc. Polymer bifocal lens production process
US5316702A (en) * 1992-07-20 1994-05-31 Innotech, Inc. Method of producing durable bonds between an optical preform and an optical resin layer cast on the preform surface
US5358672A (en) * 1992-06-08 1994-10-25 Innotech, Inc. Method for removing finished articles from glass, plastic or metallic molds
US5361168A (en) * 1991-04-30 1994-11-01 Canon Kabushiki Kaisha Lens element and lens barrel
US5470892A (en) * 1992-05-01 1995-11-28 Innotech, Inc. Polymerizable resin for forming clear, hard plastics
US6038077A (en) * 1997-08-19 2000-03-14 U.S. Philips Corporation Optical imaging system
US6091532A (en) * 1993-06-18 2000-07-18 Canon Kabushiki Kaisha Optical element, method of molding the same, and laser scanning optical system
US6551530B2 (en) * 2000-04-20 2003-04-22 Sony Corporation Method of forming a hybrid lens
US20030099783A1 (en) * 2001-11-27 2003-05-29 Fuji Photo Optical Co. Ltd. Manufacturing method of compound aspheric lens
US6649092B2 (en) 2001-04-04 2003-11-18 Lockheed Martin Corporation Plastic laminated infrared optical element
US20040131849A1 (en) * 1998-07-24 2004-07-08 Wires Duane L. Method and compositions for manufacturing plastic optical lens
WO2004095108A1 (en) * 2003-03-28 2004-11-04 3M Innovative Properties Company Low element count projection lenses for use with pixelized panels
US20050018315A1 (en) * 2003-05-01 2005-01-27 Samsung Electronics Co., Ltd. Method of manufacturing hybrid aspherical lens
US6936197B1 (en) 1998-07-24 2005-08-30 Duane L. Wires Method and compositions for manufacturing coated photochromatic articles
US20050275954A1 (en) * 2002-08-05 2005-12-15 Bloemen Pacal J H Scanning device including an objective lens formed of two materials
US20060250698A1 (en) * 2005-04-14 2006-11-09 Kazuyuki Ogura Glass optical element and manufacturing method thereof
US20080290435A1 (en) * 2007-05-21 2008-11-27 Micron Technology, Inc. Wafer level lens arrays for image sensor packages and the like, image sensor packages, and related methods
CN101313240B (zh) * 2006-12-07 2010-06-23 里程碑株式会社 摄像镜头

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JP2777371B2 (ja) * 1988-04-08 1998-07-16 大日本印刷株式会社 固体撮像素子におけるマイクロ集光レンズ形成方法
FR2638391B1 (fr) * 1988-10-27 1991-01-25 Essilor Int Procede pour le formage d'une lentille ophtalmique a partir d'un palet en matiere synthetique
JPH0416910A (ja) * 1990-05-11 1992-01-21 Omron Corp 光学レンズ
JPH0534509A (ja) * 1991-05-21 1993-02-12 Asahi Optical Co Ltd 非球面光学素子及びその製造方法
JPH07191207A (ja) * 1993-11-17 1995-07-28 Asahi Optical Co Ltd 反射型複合光学素子
US5745286A (en) * 1995-10-13 1998-04-28 Regents Of The University Of California Forming aspheric optics by controlled deposition
JP2000030278A (ja) * 1998-07-09 2000-01-28 Sony Corp 光学レンズとこれを使用した光学ピックアップ及び光ディスク装置
CN1715980A (zh) * 2004-07-02 2006-01-04 鸿富锦精密工业（深圳）有限公司 非球面镜片及其制造方法
CN100426005C (zh) * 2004-07-05 2008-10-15 鸿富锦精密工业（深圳）有限公司 眼镜片设计方法
JP4238898B2 (ja) * 2006-08-30 2009-03-18 ソニー株式会社 光学素子の製造装置
US9217854B2 (en) * 2009-04-28 2015-12-22 Cree, Inc. Lens with controlled light refraction
US10119662B2 (en) 2009-04-28 2018-11-06 Cree, Inc. Lens with controlled light refraction
US9416926B2 (en) 2009-04-28 2016-08-16 Cree, Inc. Lens with inner-cavity surface shaped for controlled light refraction
US9255686B2 (en) 2009-05-29 2016-02-09 Cree, Inc. Multi-lens LED-array optic system
US9757912B2 (en) 2014-08-27 2017-09-12 Cree, Inc. One-piece multi-lens optical member with ultraviolet inhibitor and method of manufacture

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US2890486A (en) * 1955-08-29 1959-06-16 American Optical Corp Mold for producing lens of any shape from a polymerizable material
GB1301551A (cs) * 1970-03-06 1972-12-29
GB1535986A (en) * 1975-08-22 1978-12-13 Olympus Optical Co Optical element having a replicated surface and manufacturing method therefor
US4319945A (en) * 1978-12-28 1982-03-16 U.S. Philips Corporation Method of producing aspherical optical elements
US4432832A (en) * 1982-08-26 1984-02-21 Polaroid Corporation Method of forming contoured optical layers on glass elements

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DE2133983A1 (de) * 1971-07-08 1973-01-18 Zeiss Carl Fa Asphaeren-linse
GB1362993A (en) * 1971-08-09 1974-08-14 Mullard Ltd Manufacture of optical elements
GB1362380A (en) * 1971-11-25 1974-08-07 Mullard Ltd Manufacture of optical elements
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US2253697A (en) * 1938-07-11 1941-08-26 Jenkel Davidson Optical Compan Die for molding or casting optical lenses
US2332930A (en) * 1939-10-21 1943-10-26 Rinia Herre Optical element
US2332674A (en) * 1940-08-12 1943-10-26 Univis Lens Co Method of and means for forming unbreakable lenses
US2298429A (en) * 1940-08-23 1942-10-13 Univis Lens Co Method and apparatus for automatic pressure control in molding of synthetic resinousmaterials
US2890486A (en) * 1955-08-29 1959-06-16 American Optical Corp Mold for producing lens of any shape from a polymerizable material
GB1301551A (cs) * 1970-03-06 1972-12-29
GB1535986A (en) * 1975-08-22 1978-12-13 Olympus Optical Co Optical element having a replicated surface and manufacturing method therefor
US4319945A (en) * 1978-12-28 1982-03-16 U.S. Philips Corporation Method of producing aspherical optical elements
US4432832A (en) * 1982-08-26 1984-02-21 Polaroid Corporation Method of forming contoured optical layers on glass elements

Cited By (34)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4944899A (en) * 1985-03-19 1990-07-31 Coopervision, Inc. Process and apparatus for casting lenses
US5114629A (en) * 1985-03-19 1992-05-19 Coopervision, Inc. Process for casting lenses
US5147585A (en) * 1987-10-30 1992-09-15 Blum Ronald D Method for forming plastic optical quality spectacle lenses
US5219497A (en) * 1987-10-30 1993-06-15 Innotech, Inc. Method for manufacturing lenses using thin coatings
WO1991008104A1 (en) * 1989-12-05 1991-06-13 Vision Science, Inc. Method for forming plastic optical quality spectacle
US5178800A (en) * 1990-10-10 1993-01-12 Innotech, Inc. Method for forming plastic optical quality spectacle lenses
US5290488A (en) * 1991-04-30 1994-03-01 Canon Kabushiki Kaisha Method for molding optical elements
US5292457A (en) * 1991-04-30 1994-03-08 Canon Kabushiki Kaisha Method for molding optical elements
US5361168A (en) * 1991-04-30 1994-11-01 Canon Kabushiki Kaisha Lens element and lens barrel
US5264160A (en) * 1991-04-30 1993-11-23 Canon Kabushiki Kaisha Method of molding optical elements
US5286421A (en) * 1991-06-07 1994-02-15 Canon Kabushiki Kaisha Optical element, and method and apparatus for forming the same
AU648209B2 (en) * 1991-11-29 1994-04-14 Sola International Inc. Polymer bifocal lens production process
US5366668A (en) * 1991-11-29 1994-11-22 Pilkington Visioncare Inc. Polymeric bifocal lens production process
US5470892A (en) * 1992-05-01 1995-11-28 Innotech, Inc. Polymerizable resin for forming clear, hard plastics
US5358672A (en) * 1992-06-08 1994-10-25 Innotech, Inc. Method for removing finished articles from glass, plastic or metallic molds
US5316702A (en) * 1992-07-20 1994-05-31 Innotech, Inc. Method of producing durable bonds between an optical preform and an optical resin layer cast on the preform surface
US6091532A (en) * 1993-06-18 2000-07-18 Canon Kabushiki Kaisha Optical element, method of molding the same, and laser scanning optical system
US6038077A (en) * 1997-08-19 2000-03-14 U.S. Philips Corporation Optical imaging system
US20040131849A1 (en) * 1998-07-24 2004-07-08 Wires Duane L. Method and compositions for manufacturing plastic optical lens
US7276189B2 (en) 1998-07-24 2007-10-02 Wires Duane L Method and compositions for manufacturing plastic optical lens
US6936197B1 (en) 1998-07-24 2005-08-30 Duane L. Wires Method and compositions for manufacturing coated photochromatic articles
US6551530B2 (en) * 2000-04-20 2003-04-22 Sony Corporation Method of forming a hybrid lens
US6649092B2 (en) 2001-04-04 2003-11-18 Lockheed Martin Corporation Plastic laminated infrared optical element
US20030099783A1 (en) * 2001-11-27 2003-05-29 Fuji Photo Optical Co. Ltd. Manufacturing method of compound aspheric lens
US6872334B2 (en) * 2001-11-27 2005-03-29 Fuji Photo Optical Co., Ltd. Manufacturing method of compound aspheric lens
US7149040B2 (en) 2002-08-05 2006-12-12 Koninklijke Philips Electronics N.V. Scanning device including an objective lens formed of two materials
US20050275954A1 (en) * 2002-08-05 2005-12-15 Bloemen Pacal J H Scanning device including an objective lens formed of two materials
WO2004095108A1 (en) * 2003-03-28 2004-11-04 3M Innovative Properties Company Low element count projection lenses for use with pixelized panels
US20050018315A1 (en) * 2003-05-01 2005-01-27 Samsung Electronics Co., Ltd. Method of manufacturing hybrid aspherical lens
US20060250698A1 (en) * 2005-04-14 2006-11-09 Kazuyuki Ogura Glass optical element and manufacturing method thereof
US20100058809A1 (en) * 2005-04-14 2010-03-11 Konica Minolta Opto, Inc. Method of manufacturing a glass optical element
US8646290B2 (en) 2005-04-14 2014-02-11 Konica Minolta Opto, Inc. Method of manufacturing a glass optical element
CN101313240B (zh) * 2006-12-07 2010-06-23 里程碑株式会社 摄像镜头
US20080290435A1 (en) * 2007-05-21 2008-11-27 Micron Technology, Inc. Wafer level lens arrays for image sensor packages and the like, image sensor packages, and related methods

Also Published As

Publication number Publication date
EP0150537A3 (en) 1985-08-14
JPS60154014A (ja) 1985-08-13
NL8400152A (nl) 1984-10-01
EP0150537B1 (en) 1988-04-27
EP0150537A2 (en) 1985-08-07
US4738516A (en) 1988-04-19
DD231315A5 (de) 1985-12-24
DE3470686D1 (en) 1988-06-01
CS252824B2 (en) 1987-10-15
KR850005324A (ko) 1985-08-24
CS28585A2 (en) 1987-03-12

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